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I wanted to make a costume for going to events that had better visibility than my Fett, and wasn't as clunky due to the jetpack. I really liked the Sith Inquisitor art for the game The Old Republic (TOR), but I haven't learned how to use my sewing machine yet and we had an event coming up so I decided to do the whole project with duct tape. Here's what I was going for (more or less):

and here's what I ended up with:

I also made some costumes for my kids, they wanted to be Gundams. The 3 costumes took me about 3 months to make, and I didn't really finish any of them but I think they turned out pretty good.

Thanks for all the positive feedback. It was a lot of work, and I learned a lot of lessons along the way to improve upon my design next time.

I started with sketching out the various design elements in order to figure out exactly what I needed to make:

Then I started on the legs. I used black posterboard cut into long strips held together by duct tape and some staples at stressed joints (and I added a zipper at the back). I used newspaper for the horizontally-striped parts which was much more flexible, but wrinkled a lot when I applied the duct tape. In hindsight, the posterboard was too stiff and I probably should've used some butcher paper for the whole thing instead.

For the mask, I used a basic 3M dust mask ($7 on Amazon). I printed out the Imperial/Sith emblem and covered it with clear packing tape before gluing it to the front of the mask to cover the 3M marking. i used the tops of empty Coke bottles for the tube connections, but had to skip the tubes entirely due to time constraints. A dremel tool was used for cutting/notching the plastic parts:

For the chest, I bought some cheap automotive rubber floor mats and layered them with cardboard and duct tape. I used a heavy duty stapler to hold most of the layers together. I used some screws of various sizes to connect the layers together and attach the cowl. There is some foam (from floor matting) that I used above the shoulders to allow some flexibility with the cowl.

The cowl and shoulder pieces are made from some plastic trash can and storage bin parts. I used cereal box cardboard to mock up each piece before cutting out the plastic parts.

I used some leftover plastic bin parts to make the belt buckle (front & rear). For the front, I cut out a slot for the red strip, used wax paper to make it opaque, then inserted a foil-lined trough and a red LED light to make it glow. A ton of hot glue was used to put it all together. The belt itself is made of 3 Coke bottles (the smooth center bit, cut out), some more posterboard, an old belt, lots of staples & tape, and some quick-release pager clips to hold my sabers. The rear sections of the tubes are connected to the rear belt buckle with velcro (to make it possible to put it on when connected to the rest of the costume).

Connecting the belt to the legs was one of the most challenging parts of this build, lol:

The bracers were made from the corners of the plastic bin I cut up, and the gloves were just cheap BMX gloves I found on Amazon (but looked great!)

- - - Updated - - -

Unfinished items:
I had some tubes to go from the mask to the rear section of the cowl, but I couldn't find a mounting option that I was happy with. I also designed a cowl-mounted PA system with a microphone that was supposed to be installed inside the tubes to add a robotic, heavy-breathing effect when I spoke (worked well in mock-up). I considered making a cape, but in the end I decided that it was unnecessary. My makeup was rushed and I tore my colored contacts (red/yellow... very sith-like), but the final look was very close to what I wanted.